Failure mechanisms and surface treatment processes of thermal barrier coatings: Review

Thermal Barrier Coatings (TBCs) technology is key to improving the service temperature and the productivity of aircraft engines. The performance and failure life of TBCs are strongly influenced by surface integrity and microstructure. Therefore, recognizing failure mechanisms and developing effective surface treatment processes are crucial for further improving the reliability and durability of TBCs. This paper explains the primary reasons for TBC failure, emphasizing on how integrity of surface and interface influences interfacial oxidation, high-temperature erosion, and Calcium-Magnesium-Alumina-Silicate (CMAS) corrosion. Furthermore, this paper completely and rigorously evaluates the research status of TBCs surface treatment processes, including the characteristics and effects of various processes, and describes the requirements and goals of pre-treatment and post-treatment. In addition, a potential direction for the development and application of TBCs surface treatment is suggested.